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SEMINAR on INFLUENCES OF GRAIN SIZE ON SURFACE ROUGHNESS AND GRINDING FORCES WHEN GRINDING

NITHIN dev S1 MTECH

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OVERVIEW

To investigate the influences of grinding wheel grain size when surface grinding hardened AISI 1050 steel Dynamometer was used to measure force tests were also carried out.
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Force

Grinding

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INTRODUCTION
Grinding

- The oldest surface processing method.

Some

natural materials scratched the others and resulted in wear in these other materials when they were slid against each other under pressure. These hard materials are called abrasives.
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Grinding

shapes workpieces with the required geometry, dimensions and tolerances. In grinding terminology, increasing grain number means decreasing grain size.

Wearing of abrasives and its detachment from grinding wheel is a factor which affects the grinding process. of workpieces in grinding is one of the important steps

Fastening

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1. MECHANICS OF CHIP FORMATION

Ideal

cutting can be obtained by many process combinations like workpiece movement, grinding wheel movement, elasticity of the workpiece and vibration. formation in grinding process can be divided into three successive stages:

Chip

Friction stage. Ploughing stage. Cutting stage (or) chip formation stage.
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Vs- grinding velocity. Vw- table speed. a- wheel depth of cut. hm-length undeformed of chip.

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2. MATERIALS AND METHOD

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To

measure grinding forces, force dynamometer was used. material used was AISI 1050 steel in rectangular blocks of 15 x 15 x 100 mm. Chemical composition of AISI 1050 steel:

Workpiece

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Before

the tests, AISI 1050 specimens were heat treated and stress relief annealed.

Hardness

of this material was found to be as 50 HRc by INSTRON WOLPERT DIA 7571 hardness measuring device tests carried out using TAKSAN TYT-400 surface grinder. Two components of the grinding forces ( Ft and Fn) were measured.
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Grinding

 Grain

numbers of 36, 46, 60 and 80 Aluminium oxide grinding wheels were used.

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porosity and grain size of different grinding wheels.

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The

grinding tests were carried out at depth of cuts of

 The

wheel 350 mm in diameter was run at a constant revolution of 1596 rev/min. Table feed was 460mm/s. to each test, the grinding wheel was dressed and restore by diamond. roughness values (Ra) of all the ground surfaces were measured using a MITUTOYO Surftest 211 surface measuring device.

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Prior

Surface

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3. RESULT AND DISCUSSIONS

For

the grinding tests,

grinding wheel grain size changing. depth of cuts grinding wheel revolution, wheel dressing rate flow rate of coolant kept constant.
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Tangential

force (Ft) and normal force (Fn) components were measured during grinding. sum of Ft and Fn is regarded as the grinding force. The equation is given as,

Vector

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3.1 Grinding Wheel Grain Size Surface Roughness Relation

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Variation

of mean surface roughness (Ra) values obtained after grinding with grinding wheels of 36, 46, 60 and 80 grain and at depth of cuts of 0.01-0.06 mm. 36 grain results, surface roughness values (Ra) between 1.29 and 2.56 m, Ra increasing with increasing depth of cut.
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For

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Increasing

depth of cut beyond 0.03 mm increases the difference between the surface roughness values. value for 46,60 and 80 grain size.
0.63-1.11 m for grinding wheel of 46 grain. 0.46-0.80 m for grinding wheel of 60 grain. 0.37-0.81 m for grinding wheel of 80 grain.

Ra

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The

lowest surface roughness value obtained for grinding wheel of 80 grain. grinding wheel abrasive grain size led to increase in surface roughness values. variation range becomes larger with increasing grinding wheel grain size.

Increasing

Roughness

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To

show the influence of grinding wheel grain size on surface roughness value, arithmetical average of the surface roughness values obtained using the grinding wheels of same grain were obtained.
Ra(avg)=[(Ra(td=0.01 mm))+(Ra(td=0.02 mm))+ ++ (Ra(td=0.06 mm))]/6 . td depth of cuts

By

using these arithmetical average values, the graph was plotted. Surface roughness values were seen to increase significantly with increasing grinding wheel 16 16 grain size.

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It

show that a small increase in grain size leads to considerable increases in ground surface roughness values.

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 The

image shows increasing the depth of cut and grinding wheel grain size, increases the depth and width of the grooves.

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Grinding

with grinding wheel of 46 grain at 0.02 mm depth of cut produced larger grooves in fig a, while decreasing grain size led to smaller grooves in fig b and c.
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In

fig 5a, Small dirt and crater wear due to detached grains were observed after grinding with grinding wheel of small grain size (80 grain) at 0.02 mm depth of cut. fig 5b and 5c, shows the harmful effects of higher depth of cuts, which depends on grain size.

In

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It

show small parts of workpieces filling the porosities on the grinding wheel. white areas indicating the filled porosities on the grinding wheel. results in deterioration in surface roughness.
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The It

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Detachment

of the grinding wheel grains during grinding reduces the diameter of the wheel. grains embedded into the workpiece results in scratches on the workpiece and grain detachment. cause undesirable results during service life of the parts.

The

It

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Increasing

depth of cut deepened and widened the grinding marks as grooves on the ground surfaces. that at all stages of this study, surface roughness values significantly increased with increasing depth of cut.

Observed

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3.2 Grinding Wheel Grain Size Grinding Force Relation

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It

shows the influence of grinding wheel grain size on grinding forces at 0.01-0.06 mm depth of cuts.

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The

force dynamometer was used to measure and

record the forces during surface grinding .

Grinding

forces were recorded as,

1.93-16.8 N for 46M5 grinding wheels. 1.9-13.82 N for 60M5 grinding wheels . 1.7-9.18 N for 80M5 grinding wheels.
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It

found that grinding forces increased with increasing grinding wheel grain size at 0.03 mm depth of cut. contact area increases the friction and workpiece temperature during grinding. As the result, residual stresses occur on the workpiece. stress results in small cracks on the ground

Larger

Residual

surface.
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1st

figure gives the variation of surface roughness values depending on grinding wheel grain size and depth of cut. figure gives the variation of grinding force for
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2nd

the same parameter.

CONCLUSION
Increasing

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grinding wheel grain size increased the surface roughness values and the grinding forces.

At

0.01-0.05 mm depth of cuts, the surface quality (in terms of Ra) obtained by 80 grain wheel was better than 36, 46 and 60 grain wheels.
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At higher depth of cuts, some burns and cracks were observed on the ground surface.

Grooves,

burns can be decreased if depth of cut is reduced when using grinding wheels with small grains.

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REFERENCES
Strojniki

vestnik - Journal of Mechanical Engineering 56(2010)7-8, 447-454 ,UDC 621.795:621.922.025. Technology- R K Jain, khanna Publishers Technology- G.K.Vijayaraghavan.

Production

Manufacturing

Production

Technology O.P. Khanna

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NAMASTE !!

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